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Removal And Installation: Engine: Removal

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  1. With the vehicle in NEUTRAL, position it on a hoist. REFER to JACKING AND LIFTING for lifting points.
  2. Remove the cowl panel. REFER to COWL PANEL .
  3. Release the fuel system pressure. REFER to FUEL SYSTEM PRESSURE RELEASE .
  4. Remove the engine ACL  and ACL  outlet pipe. REFER to INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW .
  5. Remove the battery tray. REFER to BATTERY AND BATTERY TRAY - EXPLODED VIEW .
  6. Disconnect the engine wiring harness electrical connector.
    • Remove the stud bolt and the ground wire.
    Fig 1: Locating Engine Wiring Harness Electrical Connector And Stud Bolt
    G08028759Courtesy of FORD MOTOR CO.
  7. Disconnect the power feed electrical connector from the positive battery terminal.
    • Remove the nut and disconnect the power feed wire from the positive battery terminal.
    Fig 2: Locating Power Feed Electrical Connector And Nut
    G08028760Courtesy of FORD MOTOR CO.
  8. NOTE: Keep the TCM electrical connector straight when disconnecting it or damage to the connector terminals can occur.

    Disconnect the TCM electrical connector.

    1. Lift the locking clip up.
    2. Slide the electrical connector straight out of the TCM.
    Fig 3: Sliding Electrical Connector Straight Out Of TCM
    G08028761Courtesy of FORD MOTOR CO.
  9. Detach the wiring harness and the vacuum hose retainers from the TCM bracket.
    Fig 4: Locating Vacuum Hose Retainers And Wiring Harness From TCM Bracket
    G08030979Courtesy of FORD MOTOR CO.
  10. Remove the 2 nuts, the bolt and the TCM bracket.
    Fig 5: Locating TCM Bracket Bolts And Nuts
    G08030980Courtesy of FORD MOTOR CO.
  11. Loosen the clamp and disconnect the CAC inlet tube.
    Fig 6: Locating CAC Inlet Tube Clamp
    G08028764Courtesy of FORD MOTOR CO.
  12. Loosen the clamp and disconnect the CAC outlet tube.
    Fig 7: Locating CAC Outlet Tube Clamp
    G08030997Courtesy of FORD MOTOR CO.
  13. Loosen the 4 retainers and remove the underbody shield.
    Fig 8: Locating Underbody Shield Retainers
    G08030560Courtesy of FORD MOTOR CO.
  14. Drain the engine cooling system. REFER to COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.0L GTDI .
  15. Disconnect the oil cooler inlet and outlet hose quick connect couplings.
    Fig 9: Locating Oil Cooler Inlet And Outlet Hose Quick Connect Couplings
    G08028767Courtesy of FORD MOTOR CO.
  16. Remove the degas bottle. REFER to DEGAS BOTTLE .
  17. Loosen the 2 clamps and disconnect the upper radiator hose and the heater hose.
    • Disconnect the heater hose quick connect coupling.
    • Detach the hoses from the 2 retaining clips.
    Fig 10: Locating Heater Hose Quick Connect Coupling Retaining Clips
    G08028768Courtesy of FORD MOTOR CO.
  18. Disconnect the lower radiator hose and clamp.
    Fig 11: Locating Lower Radiator Hose And Clamp
    G08028769Courtesy of FORD MOTOR CO.
  19. Disconnect the vacuum tube quick connect coupling from the brake booster. REFER to Disconnect - Type 1. Refer to QUICK CONNECT COUPLING .
    Fig 12: Locating Vacuum Tube Quick Connect Coupling From Brake Booster
    G08028770Courtesy of FORD MOTOR CO.
  20. Disconnect the selector lever cable end from the manual control lever, remove the 2 bracket bolts and position the selector lever cable and bracket aside.
    Fig 13: Locating Selector Lever Cable And Bracket Bolts
    G08031035Courtesy of FORD MOTOR CO.
  21. Disconnect the fuel supply tube. REFER to Disconnect - Type 2. Refer to QUICK CONNECT COUPLING .
    Fig 14: Locating Fuel Supply Tube Coupling
    G08028772Courtesy of FORD MOTOR CO.
  22. Disconnect the EVAP  tube. REFER to Disconnect - Type 2. Refer to QUICK CONNECT COUPLING .
    Fig 15: Locating EVAP Tube Coupling
    G08028773Courtesy of FORD MOTOR CO.
  23. Disconnect the wiring harness electrical connector and the PCM electrical connector.
    • Detach the wiring harness retainer.
    • Push the wiring harness retainer tabs in and slide the wiring harness up and out of the bulkhead.
    Fig 16: Locating PCM Electrical Connector
    G08033394Courtesy of FORD MOTOR CO.
  24. Detach the 3 wiring harness retainers from the valve cover stud bolts.
    Fig 17: Locating Wiring Harness Retainers
    G08028775Courtesy of FORD MOTOR CO.
  25. Remove the bolt and the ground cable.
    Fig 18: Locating Ground Cable Bolt
    G08028776Courtesy of FORD MOTOR CO.
  26. Remove the catalytic converter. REFER to CATALYTIC CONVERTER - 2.0L GTDI .
  27. Remove the front subframe. REFER to SUBFRAME - FRONT . Position the stabilizer bar aside and support with a length of mechanics wire.
  28. Remove the 2 nuts and slide the RH halfshaft assembly out of the transaxle.
    • Position the halfshaft aside and support with a length of mechanics wire.
    Fig 19: Locating RH Halfshaft Assembly Out Of Transaxle Nuts
    G08031043Courtesy of FORD MOTOR CO.
  29. Using 205-832  and 100-001  (T50T-100-A), separate the halfshaft from the transaxle.
    • Position the halfshaft aside and support with a length of mechanics wire.
    Fig 20: Separating Halfshaft From Transaxle Using Halfshaft Remover And Slide Hammer
    G08031044Courtesy of FORD MOTOR CO.
  30. Remove the drain plug and drain the engine oil, then install the drain plug.
    • 27 Nm (20 lb-ft).
    Fig 21: Locating Engine Oil Drain Plug
    G08028662Courtesy of FORD MOTOR CO.
  31. Remove and discard the engine oil filter.
    Fig 22: Discarding Engine Oil Filter
    G08028649Courtesy of FORD MOTOR CO.
  32. Remove the 2 transaxle-to-oil pan bolts.
    Fig 23: Locating Transaxle-To-Oil Pan Bolts
    G08028781Courtesy of FORD MOTOR CO.
  33. Remove the secondary latches from the transaxle fluid cooler tubes at the transaxle fluid CBV  .
    Fig 24: Identifying Secondary Latches From Transaxle Fluid Cooler Tubes At Transaxle Fluid
    G08031050Courtesy of FORD MOTOR CO.
  34. Using 307-569  , disconnect the transaxle fluid cooler tubes from the transaxle fluid cooler thermal bypass valve.
    Fig 25: Disconnecting Transaxle Fluid Cooler Tubes From Transaxle Fluid Cooler Thermal Bypass Using Tool TOC Line
    G08031051Courtesy of FORD MOTOR CO.
  35. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt from the A/C  compressor.
    Fig 26: Rotating Accessory Drive Belt Tensioner Counterclockwise
    G08033341Courtesy of FORD MOTOR CO.
  36. Disconnect the 2 A/C  compressor electrical connectors.
    • Detach the wiring harness retainer from the A/C  tube stud bolt.
    Fig 27: Locating A/C Compressor Electrical Connector And Tube Stud Bolt
    G08028667Courtesy of FORD MOTOR CO.
  37. Remove the A/C  tube bracket bolt.
    Fig 28: Locating A/C Tube Bracket Bolt
    G08028786Courtesy of FORD MOTOR CO.
  38. Remove the A/C  compressor nut, stud and the 2 bolts.
    • Position the A/C  compressor aside and support with a length of mechanics wire.
    Fig 29: Locating A/C Compressor Nut, Stud And Bolts
    G08028668Courtesy of FORD MOTOR CO.
  39. NOTE: Position a block of wood under the transaxle.

    Install the 300-OTC1585AE  and 014-00001  .

    Fig 30: Installing Power Train Lift And Adjustable Grip Under Transaxle
    G08028788Courtesy of FORD MOTOR CO.
  40. Remove the 4 nuts, the 3 bolts and the engine support insulator.
    Fig 31: Locating Engine Support Insulator Nuts And Bolts
    G08028749Courtesy of FORD MOTOR CO.
  41. Remove the transaxle support insulator bolt.
    • Lower the engine and transaxle from the engine compartment.
    Fig 32: Locating Transaxle Support Insulator Bolt
    G08028790Courtesy of FORD MOTOR CO.
  42. Remove the starter cable cover and the 2 nuts.
    • Detach the 2 wire terminals from the starter.
    • Remove the nut and the ground wire from the starter stud bolt.
    Fig 33: Locating Starter Cable Cover And Nuts
    G08030517Courtesy of FORD MOTOR CO.
  43. Remove the 2 stud bolts and the starter.
    Fig 34: Locating Starter Stud Bolts
    G08030518Courtesy of FORD MOTOR CO.
  44. Remove the starter insulator.
    Fig 35: Locating Starter Insulator
    G08031039Courtesy of FORD MOTOR CO.
  45. NOTE: Only rotate the engine in a clockwise direction or engine damage will occur.
    NOTE: Mark one stud and the flexplate for assembly reference.

    Remove and discard the 4 torque converter nuts.

    Fig 36: Discarding Torque Converter Nuts
    G08031040Courtesy of FORD MOTOR CO.
  46. Detach the wiring harness retainer from the transaxle-to-engine stud bolt.
    Fig 37: Locating Transaxle-To-Engine Stud Bolt And Wiring Harness Retainer
    G08031037Courtesy of FORD MOTOR CO.
  47. Position the generator cap aside and remove the nut and wire terminal.
    • Disconnect the wire harness electrical connector.
    • Detach the 4 wiring harness retainers from the engine.
    Fig 38: Locating Wiring Harness Retainers From Engine
    G08028796Courtesy of FORD MOTOR CO.
  48. Disconnect the PCV  tube from the turbocharger inlet pipe and position it aside.
    Fig 39: Disconnect PCV Tube From Turbocharger Inlet Pipe
    G08028797Courtesy of FORD MOTOR CO.
  49. Using the 300-OTC1819E  and 303-D089  (D93P-6001-A3) remove the engine and transaxle from the 300-OTC1585AE  .
    Fig 40: Removing Engine Transaxle From Power Train Lift Using Floor Crane And Spreader Bar
    G08028798Courtesy of FORD MOTOR CO.
  50. Remove the 3 transaxle-to-engine bolts.
    Fig 41: Locating Transaxle-To-Engine Bolts
    G08028799Courtesy of FORD MOTOR CO.
  51. Remove the 3 engine-to-transaxle bolts.
    Fig 42: Locating Engine-To-Transaxle Bolts
    G08028800Courtesy of FORD MOTOR CO.
  52. Remove the 2 transaxle-to-engine bolts and stud bolt.
    Fig 43: Locating Transaxle-To-Engine Bolts And Stud Bolt
    G08031038Courtesy of FORD MOTOR CO.
  53. Separate the engine and transaxle and install the 307-566  and bolt.
    Fig 44: Installing Torque Converter Retainer And Bolt
    G08028802Courtesy of FORD MOTOR CO.
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